Filters
5 products
Not sure it fits your truck?
Our Wildwood, FL techs will confirm the right part for your build before you buy.
Call or Text (352) 722-5295Intercooler and piping on the 1994-1998 Ram 5.9L Cummins
On the 12-valve 5.9L Cummins, the Holset HX35 turbo pushes compressed air forward to an air-to-air intercooler mounted in front of the radiator. The cooled charge comes back through the charge pipe and rubber boots into the cast intake air horn. Dodge made the intercooler standard on every 1994-1998 truck; first-gens had picked it up in mid-1991. Stock boost on the HX35 runs about 18-22 psi, and every boot and clamp in that path has to hold it.
What fails and why
Boots. Slipping or splitting under the clamps is the number-one intake-side problem on these trucks, and it happens at any age. Low power, smoke and a whistle under boost are the signs. Owners often blame the fuel system first, so check the boots before you touch the pump.
Heat soak. The other complaint on this side of the system is heat soak, and replacement intercooler cores are the fix for it. Charge temperature is one of only two things the intake side controls on this engine; the other is airflow.
Stock replacement vs. upgrade
Air-to-air intercooling is treated as mandatory on any street 12-valve, so the question is not whether to run one but which one. If the core is sound and only the boots keep slipping, a silicone boot kit and better clamps are the fix. If you are dealing with heat soak or adding power, a replacement core is the next step. Direct-fit drop-in cores for 1994-2002 trucks are one route, and larger aftermarket cores show up on compound-turbo builds. These parts handle charge temperature and sealing only; they do not add fuel.
What we carry
- Intercoolers: the Mishimoto MMINT-RAM-94 intercooler and the XDP XD479 Xtra Cool direct-fit intercooler, both listed for 1994-2002 5.9L Cummins.
- Intercooler and pipe kit: the Mishimoto MMINT-RAM-94K, which pairs the core with intercooler piping.
- Boots and hoses: the Mishimoto MMBK-RAM-94BK factory-fit boot kit and the BD Diesel 1045210 intake hose and clamp kit, both listed for 1994-2002.
- Couplers: the PPE 515303088 3-inch silicone hump coupler.
Fitment notes
The intercoolers, pipe kit, boot kit and BD hose kit are listed for 1994-2002, so per their listings they cover both the 12-valve trucks and the 24-valve trucks built from mid-1998 through 2002. Cab, bed and 2WD or 4x4 do not appear in these listings, so a regular cab, Club Cab, Quad Cab or dually 3500 matches on year and engine. The PPE coupler is sold by size, not by truck, so measure the pipe or boot you are replacing before you order it. Verify by VIN if anything is unclear.
Frequently asked questions
Why does my intercooler boot keep blowing off?
Boots slipping or splitting under the clamps is the most common intake-side problem on 1994-1998 trucks, and it can happen at any age. Silicone boot and clamp kits are the fix. The Mishimoto factory-fit boot kit and the BD Diesel hose and clamp kit are both listed for these trucks.
Do I need an aftermarket intercooler on a stock truck?
Your truck already has one: Dodge fitted an air-to-air intercooler to every 1994-1998 Ram 2500 and 3500 with the 5.9L Cummins. A replacement core makes sense when you are fighting heat soak or adding power. If the only problem is slipping boots, start with boots and clamps.
Should I buy the intercooler alone or the kit with pipes?
If your factory pipes are in good shape, the core alone may be all you need. If you are replacing boots and pipes anyway, the Mishimoto intercooler and pipe kit handles it in one order. Either way, put fresh clamps on every joint.
Not sure what fits? Call the shop at the number in the header, or use the fitment checker on any product page. We install everything we sell at our shop in Wildwood, FL.